System and method for modular building cubes spine

ABSTRACT

An umbilical corridor structure includes a plurality of hollow elongate corridor segments having a predetermined length. Each of the plurality of corridor segments includes a first end flange couplable to a complementary first end flange of an adjacent one of the plurality of corridor segments, a side flange couplable to a complementary end flange of an adjacent modular cube structure, and a plurality of service conduits extending from the end flange of the corridor segment to at least the side flange of the corridor segment.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to and the benefit of the filing date of U.S. Provisional Application No. 62/640,648, filed Mar. 9, 2018, which is hereby incorporated by reference in its entirety.

BACKGROUND

This description relates to modularly constructible facilities and, more particularly, to umbilical and support structures for modularly constructible facilities.

BRIEF DESCRIPTION

In one aspect, an umbilical corridor structure includes a plurality of hollow elongate corridor segments having a predetermined length. Each of the plurality of corridor segments includes a first end flange couplable to a complementary first end flange of an adjacent one of the plurality of corridor segments, a side flange couplable to a complementary end flange of an adjacent modular cube structure, and a plurality of service conduits extending from the end flange of the corridor segment to at least the side flange of the corridor segment.

In another aspect, a method of coupling modular structures to form modular complexes includes providing a first flange of a first modular corridor segment wherein the first flange includes a plurality of flange members coupled together using one or more cube corner assemblies. The method also includes providing a second flange of a second modular corridor segment wherein the second flange is complementary to the first flange. The second flange includes a plurality of flange members coupled together using one or more cube corner assemblies. The method further includes coupling the first flange and the second flange in a flange face-to-flange face orientation, and coupling a plurality of service conduits extending from the first flange of the first modular corridor segment to at least the second flange of the second modular corridor segment.

In yet another aspect, a cube corner assembly includes a first structural plate including a first orifice extending therethrough, a complementary second structural plate including a second orifice extending therethrough. The second orifice is approximately aligned with the first orifice. The second structural plate is spaced-apart face-to-face from the first structural plate, and a plurality of structural members extend between the first structural plate and the second structural plate.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1-11 show example embodiments of the method and apparatus described herein.

FIG. 1 is a plan view of an example umbilical corridor coupled to a plurality of modular cube structures in accordance with an example embodiment of the present disclosure.

FIG. 2 is a perspective end view of a corridor segment (shown in FIG. 1).

FIG. 3 is a plan view of a plurality of corridor segments coupled together end-to-end to form an umbilical corridor.

FIG. 4 is a plan view of another example of a modular cube structure that may be used with the umbilical corridor shown in FIG. 1.

FIG. 5 is a plan view of an example of a joint between adjacent ones of the umbilical corridor segments shown in FIG. 1.

FIG. 6 is a perspective view of an isolated pair of cube corner assemblies fixed coupled together.

FIG. 7 is a plan view of a vertical flange member of an end flange illustrating a structural column member.

FIG. 8 is a side elevation view of the example corner anchor assembly (shown in FIG. 6).

FIG. 9 is a perspective view of the example corner anchor assembly (shown in FIG. 8).

FIG. 10 is a perspective view of another example embodiment of the corner cube assembly (shown in FIG. 6).

FIG. 11 is a plan view of a corner cube assembly having eight sides for forming geodesic structures.

FIG. 12 is a flowchart of a method of coupling modular structures to form modular complexes.

Although specific features of various embodiments may be shown in some drawings and not in others, this is for convenience only. Any feature of any drawing may be referenced and/or claimed in combination with any feature of any other drawing.

Unless otherwise indicated, the drawings provided herein are meant to illustrate features of embodiments of the disclosure. These features are believed to be applicable in a wide variety of systems comprising one or more embodiments of the disclosure. As such, the drawings are not meant to include all conventional features known by those of ordinary skill in the art to be required for the practice of the embodiments disclosed herein.

DETAILED DESCRIPTION

The following detailed description illustrates embodiments of the disclosure by way of example and not by way of limitation. It is contemplated that the disclosure has general application to construction of modular facilities in industrial, commercial, and residential applications.

The following description refers to the accompanying drawings, in which, in the absence of a contrary representation, the same numbers in different drawings represent similar elements.

FIG. 1 is a plan view of an example umbilical corridor 100 coupled to a plurality of modular cube structures 102 in accordance with an example embodiment of the present disclosure. Umbilical corridor 100 is formed from a plurality of hollow elongate modular corridor segments 104 coupled together using flanges 106 formed integrally into each corridor segments 104. Corridor segments 104 have a predetermined length 108. Each of the plurality of corridor segments 104 includes a first end flange 110 couplable to a complementary second end flange 112 of an adjacent one of the plurality of corridor segments 104. Each of the plurality of corridor segments 104 may also include a side flange 114 couplable to a complementary end flange 116 of an adjacent modular cube structure 102.

Each of the plurality of corridor segments 104 also includes a plurality of service conduits (not shown in FIG. 1) extending from end flange 116 of corridor segment 104 to at least the side flange 114 of the respective corridor segment 104. Typically, the plurality of service conduits extends from end flange 116 to an opposite end flange of corridor segment 104.

FIG. 2 is a perspective end view of a corridor segment 104 (shown in FIG. 1). In the example embodiment, corridor segment 104 includes a floor member 202 and a roof member 204 extending the predetermined length 108. Second end flange 112 circumscribes a hollow passageway interior 206. Second end flange 112 includes a frame 207 formed of a plurality of members coupled together to provide a mating surface 208 for adjacent corridor segments 104 to be connected together. Second end flange 112 includes a vertical flange member 210 including a structural column member 212 and a cube corner assembly 214 fixedly coupled to at least one end of structural column member 212. In some embodiments, second end flange 112 includes a single cube corner assembly 214 in at least some corners of second end flange 112. In other embodiments, second end flange 112 includes a plurality of single cube corner assemblies 214 in at least some corners of second end flange 112. While described as being couplable together end-to-end, adjacent corridor segments 104 can also be configured to couple together side-by-side.

A plurality of service conduits 216 may extend between the first end flange 110 and second end flange (not shown in FIG. 2) within floor member 202 and/or within roof member 204. A distal end 218 of conduits 216 are fitted with couplings (not shown in FIG. 2) that are complementary with couplings of an adjacent corridor segment 104. In various embodiments, the plurality of service conduits include at least one of electrical supply conduits, control and instrumentation signal conduits, plumbing conduits, sewer/waste liquid conduits, heating, ventilating, and air conditioning (HVAC) conduits, and security and surveillance signal conduits.

FIG. 3 is a plan view of a plurality of corridor segments 104 coupled together end-to-end to form an umbilical corridor 100.

FIG. 4 is a plan view of another example of a modular cube structure 102 that may be used with umbilical corridor 100 shown in FIG. 1. In the example embodiment, modular cube structure 102 includes a plurality of rooms, which may be configured to support a particular step of a process. The process may entail the cultivation of plant or animal life, the harvesting of the plant or animal life, processing the plant or animal life, extracting valuable materials from the plant or animal life, and preparing the residue of the plant or animal life for disposal. Some of the rooms are configured to support potentially hazardous operational steps or hazardous material within them. Some of the rooms may be subject to industrial codes or other restrictions on their construction or processes. For example, a first room 402 may be a production/operation where aspects of the process are carried out, initiated, monitored, and/or controlled. A second room 404 may include a freezer 406 and an area 408 that supports freezer process operations. A third room 410 may be used for an extraction step of the process. An extraction step may remove the valuable material from the plant or animal life being processed. Such a step may yield the valuable component being sought, waste gases, and waste solids. The waste gases may need to be captured for a forced air exhaust system 412 and exhausted outside modular cube structure 102 before the waste gas builds to a hazardous concentration. In the example embodiment, a fourth room 414 includes two additional production rooms 416 and 418 to facilitate increasing production levels of the valuable component.

FIG. 5 is a plan view of an exemplary joint 500 between adjacent ones of the umbilical corridor segments 104 (shown in FIGS. 1 and 2). A plurality of service conduits 216 may extend between the first end flange 110 and second end flange 112 within floor member 202 and/or within roof member 204 (shown in FIG. 2). A distal end 218 of conduits 216 are fitted with couplings 502 that are complementary with couplings 504 of an adjacent corridor segment 104. In some embodiments, pigtails 506 are used to bridge a gap 508 between couplings 502 and 504. Each pigtail 506 includes a length 510 of appropriate conduit 512 and mating couplings 514 on each end 516.

FIG. 6 is a perspective view of an isolated pair 600 of cube corner assemblies 214 fixedly coupled together. In the example embodiment, cube corner assembly 214 includes a first structural plate 602 and a complementary second structural plate 604 spaced-apart face-to-face and a plurality of structural members 606 extending between the first structural plate 602 and second structural plate 604. In various embodiments, cube corner assembly 214 is formed into a unitary cube-shaped structural member. As used herein, “unitary” is meant to include integrally formed, monolithic, or jointless components made into a single piece, such as, for example, through a casting process, a welding process, an additive manufacturing process, an adhering process, or combinations thereof. As used herein, “additive manufacturing” refers to any process which results in a three-dimensional object and includes a step of sequentially forming the shape of the object one layer at a time. Additive manufacturing processes include, for example, three dimensional printing, laser-net-shape manufacturing, direct metal laser sintering (DMLS), direct metal laser melting (DMLM), selective laser sintering (SLS), plasma transferred arc, freeform fabrication, and the like. One exemplary type of additive manufacturing process uses a laser beam to sinter or melt a powder material. Additive manufacturing processes can employ powder materials or wire as a raw material. Moreover, additive manufacturing processes can generally relate to a rapid way to manufacture an object (article, component, part, product, etc.) where a plurality of thin unit layers are sequentially formed to produce the object. For example, layers of a powder material may be provided (e.g., laid down) and irradiated with an energy beam (e.g., laser beam) so that the particles of the powder material within each layer are sequentially sintered (fused) or melted to solidify the layer.

In the example embodiment, first structural plate 602 is approximately square or rectangular, or other shape. First structural plate 602 and second structural plate 604 are sized and aligned with respect to each other in a face to face orientation. A structural member 606 is positioned or formed in each corner or other predetermined location that facilitates corner cube assembly 214 having structural strength sufficient to perform the functions described herein. Structural members 606, if not formed in position, are welded or otherwise fixedly secured at both ends to first structural plate 602 and second structural plate 604. At least some of structural members 606 include apertures 608 therethrough that are configured to receive mechanical fasteners, such as, but not limited to bolts, to couple adjacent corner cube assemblies 214 together. In the example embodiment, first structural plate 602 and second structural plate 604 each include at least one orifice therethrough wherein the at least one orifice is aligned with respect to each other.

FIG. 7 is a plan view of vertical flange member 210 of end flange 110, 112 illustrating a structural column member 212. In the example embodiment, an exterior wall member 700 is coupled to a first side 702 of a respective structural column member 212. An interior wall member 704 is coupled to a second side 706 of the respective structural column member 212. In one embodiment, first side 702 is adjacent second side 706. The connection of exterior wall member 700, interior wall member 704, and structural column member 212 forms a corner joint of adjacent corridor segments 104. Structural column members 212 are joined together using fasteners 708 to form a sealed joint 710 between adjacent corridor segments 104 or between an adjacent corridor segment 104 and modular cube structure 102. In various embodiments, sealed joint 710 includes a seal member 712 sandwiched between the adjacent structural column members 212. Seal member 712 may be an 0-ring face seal type or a web seal type.

FIG. 8 is a section view of an example anchor assembly 800 for a corner cube assembly 214 that may be used with umbilical corridor 100 (shown in FIG. 1). FIG. 9 is a side elevation view of the example corner anchor assembly (shown in FIG. 8). Anchor assembly 800 may be used with corner cube assembly 214 when attachment to a curb or footing 802 is desired. In some embodiments, footing 802 is formed of concrete or other formable building material. A stud 804 is sunk into footing 802 and sealed using a concrete adhesive 806. Typically, stud 804 is only partially threaded, however, threads may extend an entire length 808 of stud 804. Stud 804 is inserted through an aperture 810 in second structural plate 604 and secured with a nut 812 threaded onto a threaded portion 814 of stud 804.

FIG. 10 is a perspective view of another example embodiment of corner cube assembly 214. In the example embodiment, corner cube assembly 214 joins three structural column members 212. Corner cube assembly 214 is cubic in this embodiment so, the three structural column members 212 are oriented orthogonally with respect to each other. In embodiments where corner cube assembly 214 is not cubic, the three structural column members 212 can be oriented at different angles with respect to each other. For example, corner cube assembly 214 can be configured to form geodesic structures where corner cube assembly 214 has more than six sides and the sides form angles that permit connecting eight structural column members 212 oriented almost planarly to form a portion of a geodesic structure.

FIG. 11 is a plan view of a connection assembly 1100 including a first structural plate 1102 and a second structural plate 1104 (behind first structural plate 1102 in the figure), each structural plate having eight edges for forming geodesic structures.

FIG. 12 is a flowchart of a method 1200 of coupling modular structures to form modular complexes. In the example embodiment, method 1200 includes providing 1202 a first flange of a first modular corridor segment. The first flange including a plurality of flange members coupled together using one or more cube corner assemblies. Method 1200 also includes providing 1204 a second flange of a second modular corridor segment wherein the second flange is complementary to the first flange. The second flange includes a plurality of flange members coupled together using one or more cube corner assemblies. Method 1200 further includes coupling 1206 the first flange and the second flange in a flange face-to-flange face orientation, and coupling 1208 a plurality of service conduits extending from the first flange of the first modular corridor segment to at least the second flange of the second modular corridor segment.

Optionally, the one or more cube corner assemblies include a coupling aperture and method 1200 includes coupling the first flange and the second flange in a flange face-to-flange face orientation using mechanical fasteners through complementary coupling apertures. Method 1200 may also include coupling the first flange and the second flange in a flange face-to-flange face orientation using a weldment. The plurality of service conduits may include at least one of an electrical supply conduit, a control and instrumentation signal conduit, a plumbing conduit, a sewer/waste liquid conduit, a heating conduit, a ventilating, and air conditioning (HVAC) conduit, and a security and surveillance signal conduit between the first flange of the first modular corridor segment to at least the second flange of the second modular corridor segment. The modular corridor segment may further include a side flange couplable to a complementary end flange of an adjacent modular cube structure wherein the method then includes coupling a plurality of service conduits extending from the end flange of the corridor segment to at least the side flange of the corridor segment.

The foregoing detailed description illustrates embodiments of the disclosure by way of example and not by way of limitation. It is contemplated that the disclosure has general application to construction of structures, in particular, modular structures. It is further contemplated that the methods and systems described herein may be incorporated into existing construction systems and structures, in addition to being maintained as a separate stand-alone structure.

It will be appreciated that the above embodiments that have been described in particular detail are merely example or possible embodiments, and that there are many other combinations, additions, or alternatives that may be included. While the disclosure has been described in terms of various specific embodiments, it will be recognized that the disclosure can be practiced with modification within the spirit and scope of the claims.

Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “about” and “substantially”, are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value. Here and throughout the specification and claims, range limitations may be combined and/or interchanged, such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise.

Also, as used herein, the terms “substantially” or “about” are intended to indicate a condition within reasonably achievable manufacturing and assembly tolerances, relative to an ideal desired condition suitable for achieving the functional purpose of a component or assembly. By way of an example, an assembly of components in “substantial” alignment to a common axis of rotation may deviate from perfectly co-axial alignment so long as all the components can rotate as intended for accomplishing the functional purpose of the assembly.

The above-described embodiments of an umbilical corridor structure provide a cost-effective and reliable means for providing a modular and expandable multi-use facility. More specifically, the umbilical corridor structure described herein facilitates assembling a variety of facilities from standard size modules having customizable interiors. In addition, the above-described modules facilitate assembling a facility having spaces matched to predetermined requirements while maintaining the cost-effectiveness of modular construction in a factory environment. As a result, the structures described herein facilitate expeditious build-out of a customized facility in a cost-effective and reliable manner.

Example structures and components for assembling a customized facility using factory-built modules are described above in detail. The structures illustrated are not limited to the specific embodiments described herein, but rather, components of each may be utilized independently and separately from other components described herein. Each system component can also be used in combination with other system components.

This written description uses examples to describe the disclosure, including the best mode, and also to enable any person skilled in the art to practice the disclosure, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the disclosure is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims. 

What is claimed is:
 1. An umbilical corridor structure comprising: a plurality of hollow elongate modular corridor segments having a predetermined length, each of said plurality of modular corridor segments comprising: a first end flange couplable to a complementary first end flange of an adjacent one of said plurality of corridor segments; a side flange couplable to a complementary end flange of an adjacent modular cube structure; and a plurality of service conduits extending from said first end flange of said corridor segment to at least the side flange of said corridor segment.
 2. The umbilical corridor structure of claim 1, wherein each of said plurality of hollow elongate modular corridor segments comprises a floor member and a roof member extending the predetermined length.
 3. The umbilical corridor structure of claim 1, wherein, said plurality of corridor segments are couplable to each other end-to-end or side-by-side.
 4. The umbilical corridor structure of claim 1, wherein said plurality of service conduits include at least one of an electrical supply conduit, a control and instrumentation signal conduit, a plumbing conduit, a sewer/waste liquid conduit, a heating conduit, a ventilating, and air conditioning (HVAC) conduit, and a security and surveillance signal conduit.
 5. The umbilical corridor structure of claim 1, wherein at least some of said corridor segments include a second end flange opposite said first end flange, and wherein said plurality of service conduits extend between said first end flange and said second end flange.
 6. The umbilical corridor structure of claim 5, wherein said first and second end flanges each includes a vertical flange member comprising a structural column member and a cube corner assembly fixedly coupled to at least one end of said structural column member.
 7. The umbilical corridor structure of claim 6, wherein said cube corner assembly is formed into a unitary cube-shaped structural member.
 8. The umbilical corridor structure of claim 6, wherein said cube corner assembly comprises a first structural plate and a complementary second structural plate spaced-apart face-to-face and a plurality of structural members extending between said first and second structural plates.
 9. The umbilical corridor structure of claim 8, wherein said first structural plate and said second structural plate each comprise at least one orifice therethrough, said at least one orifice aligned with respect to each other.
 10. The umbilical corridor structure of claim 8, wherein at least some of the plurality of structural members comprise at least one orifice configured to receive a mechanical fastener.
 11. A method of coupling modular structures to form modular complexes, said method comprising: providing a first flange of a first modular corridor segment, the first flange comprising a plurality of flange members coupled together using one or more cube corner assemblies; providing a second flange of a second modular corridor segment, the second flange complementary to the first flange, the second flange comprising a plurality of flange members coupled together using one or more cube corner assemblies; coupling the first flange and the second flange in a flange face-to-flange face orientation; and coupling a plurality of service conduits extending from the first flange of the first modular corridor segment to at least the second flange of the second modular corridor segment.
 12. The method of claim 11, wherein the one or more cube corner assemblies comprise a coupling aperture and wherein coupling the first flange and the second flange in a flange face-to-flange face orientation comprises coupling the first flange and the second flange in a flange face-to-flange face orientation using mechanical fasteners through complementary coupling apertures.
 13. The method of claim 11, wherein coupling the first flange and the second flange in a flange face-to-flange face orientation comprises coupling the first flange and the second flange in a flange face-to-flange face orientation using a weldment.
 14. The method of claim 11, wherein coupling a plurality of service conduits comprises coupling at least one of an electrical supply conduit, a control and instrumentation signal conduit, a plumbing conduit, a sewer/waste liquid conduit, a heating conduit, a ventilating, and air conditioning (HVAC) conduit, and a security and surveillance signal conduit between the first flange of the first modular corridor segment to at least the second flange of the second modular corridor segment.
 15. The method of claim 11, wherein the modular corridor segment comprises a side flange couplable to a complementary end flange of an adjacent modular cube structure, said method further comprises coupling a plurality of service conduits extending from the end flange of the corridor segment to at least the side flange of the corridor segment.
 16. A cube corner assembly comprising: a first structural plate comprising a first orifice extending therethrough; a complementary second structural plate comprising a second orifice extending therethrough, said second orifice aligned with said first orifice, said second structural plate spaced-apart face-to-face from said first structural plate; and a plurality of structural members extending between said first structural plate and said second structural plate.
 17. The cube corner assembly of claim 16, wherein a first and a second end flange each includes a vertical flange member comprising a structural column member and a cube corner assembly fixedly coupled to at least one end of said structural column member.
 18. The cube corner assembly of claim 16, wherein said cube corner assembly is formed as a unitary cube-shaped structural member.
 19. The cube corner assembly of claim 16, wherein an end flange or a side flange comprises a frame comprising a pair of vertical flange members, a pair of horizontal flange members, joined by a plurality of cube corner assemblies.
 20. The cube corner assembly of claim 16, wherein at least some of said plurality of structural members comprise at least one orifice configured to receive a mechanical fastener. 